Max Systems D508 User manual

Service Manual

For printer model:

MB400i / MB410i

www.satoamerica.com

PN: 9001193

Operator Manual

For printer model:

D508 / D512

www.satoamerica.com

PN: 9001177B

SATO America, Inc.

10350A Nations Ford Road

Charlotte, NC 28273

Main Phone: (704) 644.1650

Technical Support: (704) 644.1660

Technical Support Fax: (704) 644.1661

E-Mail: sato[email protected]

techsupport@satoamerica.com

www.satoamerica.com

WARNING

THE EQUIPMENT REFERENCED IN THIS DOCUMENT COMPLIES WITH THE REQUIREMENTS IN PART 15 OF FCC

RULES FOR A CLASS B COMPUTING DEVICE. OPERATION OF THIS EQUIPMENT IN A RESIDENTIAL AREA MAY

CAUSE UNACCEPTABLE INTERFERENCE TO RADIO AND TV RECEPTION.

i

TABLE OF CONTENTS

OVERVIEW

1.1 Introduction .......................................................................................................... 1-2

INSTALLATION

Safety Precautions..................................................................................................... 2-2

2.1 Unpacking............................................................................................................. 2-4

2.1.1 Printer Part Names........................................................................................... 2-5

2.1.1 SETTING UP THE PRINTER ............................................................................. 2-6

2.2 Loading Media..................................................................................................... 2-7

2.3 Label Sensing....................................................................................................... 2-9

CONFIGURATION AND OPERATION

3.1 Operating PANEL................................................................................................. 3-1

3.2 THE REAR PANEL ............................................................................................... 3-2

3.3 THE CONFIGURATION PANEL ........................................................................... 3-3

Switch 4: Unused ....................................................................................................... 3-4

Switch 5: Head Check................................................................................................ 3-5

Switch 6: VR1 Potentiometer Adjustment mode..................................................... 3-5

3.4 Error Codes .......................................................................................................... 3-7

3.5 Offsets................................................................................................................... 3-8

3.6 Potentiometer Adjustments ................................................................................ 3-9

3.6 Potentiometer Adjustments (Cont’d) ................................................................. 3-10

3.7 DATA Dump Diagnostic Label ............................................................................ 3-11

3.8 Printing Test Labels............................................................................................. 3-12

3.9 Printing Factory/Service Test Prints .................................................................. 3-13

CLEANING AND MAINTENANCE

4.1 Introduction .......................................................................................................... 4-1

4.2 Adjusting the Print Quality.................................................................................. 4-1

4.3 CLEANING THE PRINT HEAD, PLATEN AND ROLLERS.................................. 4-2

4.4 Releasing/Replacing the Print Head ................................................................. 4-4

4.4 Cleaning the Sensor ........................................................................................... 4-5

INTERFACE SPECIFICATIONS

5.1 Interface types...................................................................................................... 5-1

5.2 The Receive Buffer .............................................................................................. 5-2

5.3 IEEE1284 Parallel Interface ................................................................................. 5-4

5.4 RS-232C Interface ................................................................................................ 5-5

5.4.1 RS-232C Interface Signals ............................................................................... 5-6

5.5 Universal Serial Bus Interface ............................................................................ 5-7

ii

5.6 Local Area Network Interface..............................................................................5-7

5.7 WIRELESS LAN INTERFACE (802.11 b/g)..........................................................5-8

TROUBLESHOOTING

6.1 Initial Checklist .....................................................................................................6-1

6.2 Checking the IEEE1284 Parallel Interface..........................................................6-1

6.3 Error Signals.........................................................................................................6-5

6.3 Checking the 802.11G Wireless Interface ..........................................................6-6

SATO CONTACTS

SATO Group of companies .......................................................................................7-2

Section 1: Introduction

SATO D508/D512 Operator Manual Page 1-1

1

OVERVIEW

Thank you for your investment in this SATO printer product.

This Operator’s Manual contains basic information about the installation, setup,

configuration, operation and maintenance of the printer.

A total of seven topics are covered herein, and they are organized as follows:

Section 1: Introduction

Section 2: Installation

Section 3: Configuration and Operation

Section 4: Cleaning and Maintenance

Section 5: Interface Specifications

Section 6: Troubleshooting

It is recommended that you become familiar with each section before installing and maintaining

the printer. Refer to the Table Of Contents at the front of this manual to search for the relevant

information needed. All page numbers in this manual consist of a section number followed by the

page number within the stated section.

Note:

All information herein was correct and current at the time of publication. The contents of this doc-

ument are subject to revision and change without prior notification to users. To obtain the most

current version of this document, refer to the SATO America website at www.satoamerica.com.

Section 1: Introduction

Page 1-2 SATO D508/D512 Operator Manual

1.1 INTRODUCTION

The SATO D508/D512 Printer Operator Manual provides information for installing and

maintaining D508/D512 Direct Thermal printers. It is recommended that you become familiar with

each section in this manual before installing and maintaining the printer.

The major difference in the D508 and the D512 printers is the resolution of the print head. The

D508 with its 203 dpi head provides an economical labeling solution for most applications. The

D512's higher 305 dpi resolution provides greater detail for graphics and small point size text.

The D5 Series printers use a subset of the standard SATO Command Language. The D508 and

D512 share the same command set, the only differences are the allowable values representing

the print positions on the label. These values are specified in "dots" and will vary depending upon

the resolution of the printer and the amount of memory available for imaging the label. The allow

-

able range for each printer is specified in a table for those command codes. In addition, users

can choose an interface—such as parallel (IEEE1284), serial (RS-232C), Ethernet (10/100-

BaseT), USB 1.1and Wireless LAN IEEE 802.11b.

The following general information is presented in this section:

• General Printer Specifications

Section 1: Introduction

SATO D508/D512 Operator Manual Page 1-3

1.1 GENERAL PRINTER SPECIFICATIONS

Attribute

PRINT

Print Method Direct Thermal

CPU 32-bit RISC processor

Printer Command Language SATO (SBPL) and PCL5e Subset

Font / Symbologies

Font

Linear Barcode

2-D Barcode

Font

Linear Barcode

2-D Barcode

SATO Printer Command Language (for 203 dpi and 305 dpi):

U, S, M, WB, XS, XU, XM, XB, XL, OUTLINE, OCR-A, OCR-B,

WL, CG Times, CG Triumvirate

UPC-A, UPC-E, EAN-8, EAN13, Code 39, Code 93, Code 128,

Codabar, MSI, Bookland, Industrial 2/5, Interleaved 2/5, Matrix 2/5,

Postnet, UCC/EAN 128, RSS Composite Code

PDF417, Micro PDF417, Truncated PDF417, Maxicode, Data matrix,

QR Code

PCL5e Subset (Optional for 305 dpi only):

CG Triumvirate Bold Condensed Bold, Univers Medium, Univers Bold,

Courier Regular, OCR-A, OCR-B, Roman Pillar Regular, Roman Pillar

Bold, Roman Pillar Italic, Roman Pillar Bold Italic (supports Universal

Font Scaling Technology Ver. 4.1)

UPC-A, UPC-E, EAN-8, EAN13, Code39, Cjode 93, Code 128, MSI,

Bookland, Indusstrial 2/5, Interleaved 2/5, Matrix 2/5, Postnet, UCC/

EAN 128

PDF417, Maxicode

Font Memory 4 MB

Print Head Resolution 8 dots per mm for 203 dpi | 12 dots per mm for 305 dpi

Print Speed For D508: 6 ips (150 mm/second)

For D512: 4 ips (100 mm/second)

Max. Print Area 4.1” (104 mm) W by 15.7” (400 mm) L

Section 1: Introduction

Page 1-4 SATO D508/D512 Operator Manual

1.1 GENERAL SPECIFICATIONS (CONT’D)

Attribute

MEDIA

Media Type Roll and fanfold

Label Thickness

(Label + backing paper)

0.0026” (0.6 mm*) - 0.007” (* 0.19 mm)

*Check with your dealer regarding conditions

for using thin 0.002” (06 mm) labels

Label Form Roll Label: Maximum outer diameter of 4.33” (110 mm) face out

Core Inner Diameter of 1.5” (40 mm)

Outer Diameter: 4.33” (110 mm)

Fan-fold label: Max. foldable height: 3.94” (100 mm) loaded externally)

Wind Orientation: Face-out

Label Size (adhesive labels) Width for all types:

1.1” (28 mm) - 4.65” (118 mm)

For continuous feed:

Length: 0.71” (18 mm) - 15.75” (400 mm)

For Cutter usage (optional):

Length: 1.1” (23 mm) - 15.75” (400 mm)

For Tear Off mode:

Length: 0.71” (18 mm) - 15.75” ( 400 mm)

SENSING

See-Through For die-cut label with gap: Fixed, 0.25" (6.3 mm) from left label edge

Continuous Form Sensor not used

Eye Mark Reflective sensor (for use with Pre-printed eye marks)

*All specifications subject to change without notice.

Section 1: Introduction

SATO D508/D512 Operator Manual Page 1-5

1.1 GENERAL SPECIFICATIONS (CONT’D)

Attributes

CONTROLS AND SIGNALS

On-Line LED Green

Power LED Green

Error LED Red

LED Display Panel 7-Segment Single Character

On/Off-Line Button Front Panel

Label Feed Button Front Panel

Power On/Off Button Front Panel

Self Diagnostics Head check

Paper end

Cover open

Test p r i n t

POTENTIOMETER ADJUSTMENTS

Adjustment Potentiometers VR1: Offset level (DIPSW6 = OFF)

VR1: Print darkness (DIPSW6 = ON)

VR2: Eye Mark

VR3: Gap sensor (to adjust the threshold)

VR4: Label pitch offset

DIP switches DIP-SW -1,2,3 : Operation mode(Print mode/Download mode)

DIP-SW -4 : Reserved (constantly OFF)

DIP-SW -5 : Head check (ON-Enabled / OFF-Disabled)

DIP-SW -6 : VR1 function switch

(ON-Print darkness level / OFF-Offset)

DIP-SW -7 : DATA dump (ON-HEX dump print / OFF-Normal print)

DIP-SW -8 : Reserved (constantly OFF)

INTERFACE CONNECTIONS

Parallel (Option) IEEE1284

Serial (Option) RS232C (up to 57.6K bps) Hardware Flow Control (Ready/Busy) Soft-

ware Flow Control (X-On/X-Off)

Bi-directional Status

USB (Option) USB Specification Version 1.1

LAN (Option) 10/100 Base-T

RFID (Option) TBA

Wireless LAN (Option) 802.11 b/g (internal)

*All specifications subject to change without notice.

Section 1: Introduction

SATO D508/D512 Operator Manual Page 1-6

1.1 GENERAL SPECIFICATIONS (CONT’D)

Barcodes

SYMBOLOGIES

Supported 1D formats

(excluding customized barcode

addressing in firmware)

UPC-A/E

EAN-8/EAN-13

CODABAR

CODE39

CODE93

CODE128

UCC/EAN128

Interleaved 2 of 5

Industrial 2 of 5

Matrix 2of5

RSS Composite

MSI

POSTNET

Bookland

Supported 2D formats PDF 417

Micro PDF 417

Truncated PDF 417

Maxicode

Data Matrix

QR Code

Ratios 1:2, 1:3, 2:5 User definable bar widths (depending on software)

Bar Height 4 to 600 dots (depending on software)

Rotation 0°, 90°, 180° and 270° (depending on software)

*All specifications subject to change without notice.

Physical Attributes

DIMENSIONS

Width 7.8 in. (198 mm)

Depth 9.1 in. (230 mm)

Height 6.6 in. (167 mm)

Weight 5.5 lbs (2.5 Kg) excluding AC adaptor

POWER REQUIREMENTS

Voltage USA: AC 115 V (+/- 10 %)

50/60 Hz (+/-1%)

Power Consumption 67W nominal

ENVIRONMENTAL

Operating 32° to 95°F (0° to 35°C),

30 to 80% RH, non-condensing

Storage 23° to 140°F (-5° to 60°C),

30-90% RH, non-condensing

REGULATORY APPROVALS

Safety USA : UL(UL60950-1)

CANADA : C-UL(CSA C22.2 No.60950-1-3)

EMC/EMS USA : FCC15B (ClassB)

Section 1: Introduction

SATO D508/D512 Operator Manual Page 1-7

Optional Accessories

220V Power Supply Auto-switching

Internal Cutter User or factory installed Internal option allowing

labels to be cut at specified intervals.

IEEE1284 Interface Parallel interface. Factory or User installable

Serial Interface High Speed RS232 Interface option, 9600 bps to

57.6 Kbps. Factory or User installable.

LAN Interface TCP/IP Protocol Interface option. Factory or User

installable.

USB Interface Universal Serial Bus Interface option. Factory or

User installable.

RFID To be announced

Wireless LAN Interface 802.11 b/g

*All specifications subject to change without notice.

Section 1: Introduction

SATO D508/D512 Operator Manual Page 1-8

SECTION 2: INSTALLATION

SATO D508/D512 Operator Manual Page 2-1

2

INSTALLATION

This section assists you in unpacking the printer from the shipping container. You will also be

guided through a familiarization tour of the main parts and controls. The following information is

provided herein:

• Safety Precautions

• Unpacking and Parts Identification

• Loading Media

• Adjusting the Sensor

SECTION 2: INSTALLATION

Page 2-2 SATO D508/D512 Operator Manual

SAFETY PRECAUTIONS

THE CAUTION SYMBOL

Whenever the triangular Caution logo appears in this manual, pay special attention to the warning(s) cited

below it. Failure to abide by the warnings may result in injury or damage to property.

PRINTER PLACEMENT TIPS

• Place the printer on a solid, stable, horizontal sur-

face that is not subject to strong vibrations from adja-

cent mechanical devices.

• Avoid shaky or slanting tables, or platforms that are

liable to collapse under a heavy weight. If the printer

is dropped or damaged, immediately turn off the

power, pull out the power plug and contact a service

center. In this case, continued use of the printer may

cause a fire or electric shocks.

• Avoid installing the printer in direct sunlight, or in

dusty, very hot or slippery areas. Also avoid place-

ment in damp, unventilated or humid areas. If con-

densation forms, immediately turn off the power, and

do not use the printer until the condensation disap-

pears. Otherwise the moisture may cause electric

shocks.

• Avoid placing the printer near large high-current

equipment, as such equipment can cause spikes or

undervoltages in the power supply.

• Do not leave containers of water or chemicals

around the printer. If any liquid is spilled onto

the printer, immediately turn off the power, pull

out the power cable from the AC outlet, and

contact a sales outlet, dealer, or service center.

In this case, continued use of the printer may

cause fires or electric shocks.

• Do not move the printer with any paper loaded.

The stack of paper may fall off, causing trips

and accidents.

• When laying the printer down, be careful not to

catch your foot or fingers under it.

• When moving the printer, be sure to pull out the

power cable from the AC outlet, and check that

any other external interface cables have been

disconnected. Otherwise, the connected cables

may be damaged, or may cause trips and falls,

in addition to or a fire or electric shocks.

ELECTRICAL PRECAUTIONS

• Do not damage, break, or process the power cable.

Hanging heavy objects on it, heating or pulling it may

damage the power cable and cause fires or electric

shocks.

• When the power cable is damaged (cable conductors

are exposed or cut, etc.), contact a sales outlet,

dealer, or service center. In this case, continued use

of the printer may cause fires or electric shocks.

• Do not process, forcibly bend, twist, or pull the power

cable. Continued use of such a cable may cause

fires or electric shocks.

• If the printer emits any smoke or peculiar odors at

any time, turn it OFF and prevent further usage until

you have contacted a qualified service personnel.

• Do not use any other voltage except the specified

power voltage for the printer that matches your

domestic power supply. Otherwise, it may cause fires

or electric shocks.

• Do not operate the power switch or handle the

power cable with a wet hand.

• Do not insert or drop anything metallic or flam-

mable into the openings of the printer (the cable

outlet or mounting hole of the memory car-

tridge). Otherwise, immediately turn off the

power, pull out the power cable, and contact a

sales outlet, dealer, or service center. In this

case, continued use of the printer may cause

fires or electric shocks.

• To reduce electrical risks, be sure to connect

the printer to ground before use. Also, try not to

share the printer’s AC outlet with other electri-

cal equipment, especially those that draw high

amounts of current or cause electrical interfer-

ence.

SAFETY PRECAUTIONS

Please read the following information carefully before

installing and using the printer

SECTION 2: INSTALLATION

SATO D508/D512 Operator Manual Page 2-3

This is a piece of Class B information technology equipment based on the standards of the Voluntary Control

Council for Interference by Information Technology Equipment (VCCI). Although this equipment is for use in

home environment, if it is used close to a radio or television set, it may cause poor reception. Handle it

properly in accordance with the content from the instruction manual.

GENERAL PRECAUTIONS

• When using head cleaning liquid, note that it is flam-

mable. Never heat it or throw it into a fire. Keep it out

of children’s reach to avoid accidental consumption.

Should this occur, consult a doctor immediately.

• When opening/closing the cover, beware of getting

your fingers caught. Also, hold the opening/closing

cover well so that it will not slip and fall onto the

hand.

• After printing, the print head remains hot. When

replacing paper or cleaning the printer immediately

after printing, be careful not to burn yourself.

• Touching even the edge of the printer head may

cause injuries. When replacing paper or cleaning the

printer, be careful not to hurt yourself.

• If the printer will not be used for extended periods of

time, disconnect the power cable for safety.

• When releasing and locking down the printer head,

be careful not to catch any other foreign matter in it

except label paper.

• Do not disassemble or perform modifications to

the printer, as this renders the product unsafe.

For maintenance, troubleshooting and repairs,

consult a sales outlet, dealer, or service center

for help, instead of attempting to perform this

yourself. Renewable annual service contracts

are available.

• When maintaining or cleaning the printer,

always disconnect the power cable for safety.

• Do not insert your hand or other objects into the

cutter.

• When loading roll paper, be careful not to catch

your fingers between the paper and the feeder.

• Be careful not to hurt yourself when detaching

the back cover of the fanfold through the hole

and attaching it.

• The simplified cutter (if applicable to the printer)

is structured as a blade. Be careful not to cut

yourself.

SECTION 2: INSTALLATION

Page 2-4 SATO D508/D512 Operator Manual

2.1 UNPACKING

When unpacking the printer, take note of the following:

Note:

The following parts shown here are representative only. Due to regional requirements and our policy of

continual improvement, your printer may not be packed with the exact parts as shown here, but the

unpacking steps are similar.

The box should stay right-side up.

Lift the printer out of the box carefully.

If the printer has been stored in the

cold, allow it to reach room

temperature before turning it on.

Remove the plastic covering from the

printer.

Set the printer on a solid, flat surface.

Inspect the shipping container and

printer for any sign of damage that

may have occurred during shipping.

Remove the accessory items from their

protective containers.

1

4

2

5

3

Printer AC adaptor and cable

User documentation and software

package (where applicable)

SECTION 2: INSTALLATION

SATO D508/D512 Operator Manual Page 2-5

2.1.1 PRINTER PART NAMES

Clear window and

fanfold-label Loading

Top Cover

Label Outlet

Front cover

(allows access to optional cutter unit, DIP switches

and potentiometers)

LINE/FEED/

Power

buttons and

LEDs

7-segment

Error Status LED

Release latch for Top Cover

Mini

Screwdriver

Label Holders

Thermal Print

Head assembly

Label Holder Release Knob

Platen Assembly

Label Sensor

Optional Cutter

SECTION 2: INSTALLATION

Page 2-6 SATO D508/D512 Operator Manual

2.1.1 SETTING UP THE PRINTER

Consider the following when setting up the printer:

Locate a solid flat surface with adequate room to set the printer. Make sure the AC

adaptor can be located so that the AC power cable can be attached to the printer and

an AC power outlet. The location should be near the host or computer terminal. The

maximum distance recommended is:

- 10 feet for a Parallel interface cable. Make sure it meets IEEE1284 specifications

- 18 feet for the optional Serial RS232 Interface

- 10 feet for the optional USB interface without hub

- the optional 10baseT Ethernet Interface depends upon the LAN cabling

- Up to 100m for the Wireless LAN, depending on structural conditions

Follow these steps to set up your printer:

1. Make sure the power switch on the Operator

Panel is in the OFF (0) position and place the

AC adaptor in a safe and secure location.

2. Connect the Input Power connector to the

printer. This connector is buttoned and must

be turned approximately 3/4 turn clockwise to

secure it to the printer.

3. Connect the AC Power Cable to an AC Outlet

supply of an appropriate voltage.

4. Connect the interface cable to the host system.

If you are using the Parallel Port connection, a

parallel IEEE1284 interface cable must be

used to realize the high data transfer rate of

the printer's parallel port. If another interface is

installed, the appropriate cable should be

used.

5. Load the label media following the instructions

in this section.

6. Configure the printer for label width and operating mode using the instructions in this section.

7. Press the printer power button to the ON (I) position.

8. Print a test label to verify the printer is set up and operating correctly.

SECTION 2: INSTALLATION

SATO D508/D512 Operator Manual Page 2-7

2.2 LOADING MEDIA

The SATO D508 / D512 printer can print to direct thermal die-cut labels, tags or continuous media.

The media supply can be either in Roll or Fanfold format.

Roll Media

Roll media should be between 0.98" (25 mm) and 4.3" (110 mm) in width and wound face-out on a

core with a minimum internal diameter of 1.6" (40 mm).

1. Make sure the printer is turned OFF.

2. Open the Top Cover by pressing on cover

release points located on the right-hand side

of the printer. This releases the Top Cover and

allows it to swing upward on the rear mounted

hinge points.

3. With the Top Cover in the upright position,

press the Paper Guide Release while adjust-

ing the Paper Guides until they allow a media

roll to fit between them. A millimeter scale is

molded into the case to provide a guide when

making the adjustment. The Paper Guides are

center justified and interact with each other so

that each moves an equal distance.

4. Make sure the Roll Holders are in the released

position. If they are not, lift up on each one and

they will snap to the open position.

5. Unwind approximately 12" of label material

from the roll. The labels should be wound

face-out (printing side to the outside of the

roll). Drop the roll in-between the Paper

Guides so that the labels come off the top of

the roll. The Paper Guides will automatically

position the Roll Holders to suspend the roll.

Cover/Print Head

Release Latch

Roll Holders

Paper

Sensor

Millimeter

scale

Paper Guide

Release

Label path

SECTION 2: INSTALLATION

Page 2-8 SATO D508/D512 Operator Manual

6. Route the label material through the Paper

Sensor Assembly and over the Platen. Note

that the Sensor is part of the left Label Roll

Guide so that the Paper Sensor is always

positioned in the same location relative to

the left edge of the label.

7. Close the Top Cover.

8. Press the LINE button so that the printer is

in the OFF LINE mode and then press the

FEED button. The label should advance to

the next index (label gap) position.

Fanfold media

1. Place the fanfold media behind the printer

with the printing surface up.

2. Open the Top Cover by pressing on the cover

release latch located on the right-hand side

of the printer. This releases the cover and

allows it to swing upward on the rear

mounted hinge points.

3. Carefully pull up the Fanfold-label Loading

Slot from the back of the Top Cover.

4. With the Top Cover in the upright position,

press the Paper Guide Release while adjust-

ing the Paper Guides until they allow a media

to fit between them. A millimeter scale is

molded into the case to provide a guide when

making the adjustment. The Paper Guides

are center-justified and interact with each

other so that each moves an equal distance

apart from each other.

5. Route the label material through the Sensor

Assembly and over the Platen.

Paper Sensor Paper Guide

Platen

Pull up

the

loading

slot

Pull

open

the Top

Cover

Load

the

fanfold

paper

Fanfold-label Loading slot

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